My attempt at building GL beetle
 

Hi Ive been on this site for ages, posting,snooping,admiring,researching and basically getting inspired and learning all about this GL tuning style.I would like say a massive THANKS in advance all the members on here that have given me help and advise over the years and kept me inspired by your builds and creative talents,huge respect fellas.The GL style is by far the most interesting for me as the Cal Look thing to me is old hat.I love the idea of adding big engines with tons of power,big brakes and good handling.Having an old beetle with modern perfomance to me is just the ultimate car to own.:cool::cool::cool::cool:Sadly its taken me years to get mine sorted and I aint finished yet, but I know I will have it sorted one day.

So I thought it was about time I started putting a build thread together even though I have still not finished the car. I have some outstanding problems mainly engine related.Less said about that at the moment the better.:angry:

Anyway here is a pic of my car the day I first saw it prior to buying it.[IMG]http://i1185.photobucket.com/albums/...9.jpg~original~original[/IMG]
A pretty straight never badly crunched 1303

My attempt at building GL beetl
 

the stripdown at Terrys Beetle Services in Ealing London [IMG]http://i1185.photobucket.com/albums/...f.jpg~original~original[/IMG]

Luke at Terrys has done all the bodywork and paint.

The car hiding on the right is a well known car here in the UK called Moody I think it's currently up for sale.

[IMG]http://i1185.photobucket.com/albums/...6.jpg~original~original[/IMG]

[IMG]http://i1185.photobucket.com/albums/...4.jpg~original~original[/IMG][IMG]http://i1185.photobucket.com/albums/...1.jpg~original~original[/IMG]
http://i1185.photobucket.com/albums/...8.jpg~original~original[/IMG]
[IMG]http://i1185.photobucket.com/albums/...e.jpg~original[/IMG[IMG]http://i1185.photobucket.com/albums/...0.jpg~original~original[/IMG]
These pics where taken in 2006

My attempt at building GL beetle
 

metal removal time[IMG]~original[/IMG]
[IMG]http://i1185.photobucket.com/albums/...1.jpg~original~original[/IMG]
[IMG] front removed
[IMG]http://i1185.photobucket.com/albums/...d.jpg~original~original[/IMG][IMG]http://i1185.photobucket.com/albums/...0.jpg~original~original[/IMG][IMG]http://i1185.photobucket.com/albums/...c.jpg~original~original[/IMG]
[IMG]http://i1185.photobucket.com/albums/...d.jpg~original[/IMGhttp://i1185.photobucket.com/albums/...2.jpg~original

Hi

Can't wait to see more.

Steve

That is a large pile of scrap you took off it. Can't wait to see it go back together.

My attempt at building GL beetle
 

new door,heater channel and bottom post, i cant remember who makes these bottom posts but they are a very well made panel [IMG]http://i1185.photobucket.com/albums/...8.jpg~original~original[/IMG][IMG]http://i1185.photobucket.com/albums/...9.jpg~original~original[/IMG]more replacement panels gone in.I have paid someone to do all of this as unfortunately I dont' have the skills or expertise to do it myself.I feel a bit guilty having a kind of cheque book resto carried out but its taken years to get to where the car is now I would never of been able to carry out work like this without lots of experience so decided it was best left to someone who new why he was doing ( horses for courses and all that )[IMG]http://i1185.photobucket.com/albums/...d.jpg~original~original[/IMG][IMG]http://i1185.photobucket.com/albums/...6.jpg~original~original[/IMG][IMG]http://i1185.photobucket.com/albums/...0.jpg~original~original[/IMG]

few more pics of the replacement panels[IMG]http://i1185.photobucket.com/albums/...f.jpg~original~original[/IMG]

moon vents welded up I wanted to have this done to prevent moisture getting into the rear quarters as they seem to rot badly here and to give the car a cleaner look.I am hoping on creating some kind of ducting/vents under the floor pan to introduce some more air into the engine bay for extra coolinghttp://i1185.photobucket.com/albums/...5.jpg~original
[IMG]http://i1185.photobucket.com/albums/...9.jpg~original~original[/IMG]
[IMG]http://i1185.photobucket.com/albums/...9.jpg~original~original[/IMG]more paint removal and trim holes down the side of the car welded uphttp://i1185.photobucket.com/albums/...4.jpg~original

Looks like they have done a good job there. I went to get a quote for some accident damage a while back and whilst everything they were doing looked to a top standard it was just too much for the other party...

Keep it coming :)

alot of the same body-mods i have done to my bug. as i am running a wasserboxer in mine im thinking of removing most of the ventilation under the rear window also. just for doing something different. wouldnt recommend it if going aircooled though :)

I give mad respect to anyone who goes through all this body work to get a bug on the streets. I don't know that I would have the patience for it.

My attempt at building GL beetle
 

Thanks Humble. I got to say this car has tested my patience on soooo many levels.

Your car is one that I have closely followed and now your going scooby I am following your progress once again.Great vids by the way :cool: your car seems to handle brilliantly.

My attempt at building GL beetle
 

few more pics[IMG]http://i1185.photobucket.com/albums/...b.jpg~original~original[/IMG]
[IMG][IMG]http://i1185.photobucket.com/albums/...a.jpg~original~original[/IMG]
Prior to this pic the floor pan and shell where separated and the pan was painted in POR 15 before a final coat of a rubber type spray on protection.Then the first coat of paint was cooked onto the bodywork.

My attempt at building GL beetle
 

After this pic of the car on the trailer the car was taken to a so called Subaru Engine conversion specialist.I didn't have the skills or knowledge to do the installation myself.Unfourtunately they didn't have the skills or knowledge either :angry::angry::angry: this has been a nightmare and the less said about this the better.But lets just say I was not prepared to let them get away with it so I have come down on them like :bricks:

This has now resulted in the engine,gearbox,ecu and all the other **** they fitted being removed.


Anyway
Paul and his team at type two detectives http://www.type2detectives.comas fitted the Porsche 944 s2 hubs,rear ali arms,four pot calipers, vented disks as well as the Kerscher front and rear anti roll bars and Kerscher front struts.Again these guys where great, Paul who owns the place is an honest bloke and I would highly recommend them.Paul told me that one of his guys was having a tough time with the car and really getting pissed off with it at one point but He sorted it so hats off to him so a massive TA V MUCH FELLA. these parts where cleaned and etailed prior to fitting

[IMG]http://i1185.photobucket.com/albums/...a.jpg~original~original[/IMG]
Roll cage fitted,this was done by Jim Smith of Cotsweld:notworthy: Jim has done an amazing job of the cage his welding is outstanding.http://www.cotsweld.co.uk If you are thinking of having a cage built here in the UK Jim's ya man.:cup1: Unfourtunately the pics I had of the car at Cotsweld seemed to have been lost :( so I only have some of the pics of the cage prior to paint.[IMG]http://i1185.photobucket.com/albums/...d.jpg~original~original[/IMG][IMG]http://i1185.photobucket.com/albums/...1.jpg~original~original[/IMG][IMG]http://i1185.photobucket.com/albums/...a.jpg~original~original[/IMG]

The cage was built this shape in the rear as I wanted to retain the rear seat.Not sure whats happening now though.




The ali arms where also polished.I have now got LAP rear coilovers http://www.laperformance.co.uk/blog/ ,thanks for all your inspiration Lee

I managed find the wheels and tyres on ebay, these are called Carrera Classics.I wanted these for various reasons.1.I think they suit the ergonomic shape of the beetle 2.they're are reasonably unseen on GL cars I have only seen one other car and 3. they are easy to clean,I can clean the insides without having to remove them.Tyres are Pirelli P Zero's.[IMG]http://i1185.photobucket.com/albums/...6.jpg~original~original[/IMG][IMG]http://i1185.photobucket.com/albums/...c.jpg~original~original[/IMG] thanks for looking

Looking good G.
Post up a pics of the arm polished please.
Im suprised you went for the super wide versions?

Making good progress. Love the shot of the rear of the car. There is no shame in paying people to work on your car, as we are not all experts. Looks like you have chosen well with the work you have had done. Good choice of wheels. We will have to catch up at a show.

My attempt at building GL beetle
 

The only pics of the polished arms are the ones already posted.Could take some more some time if you want .I went for the wide trailing arms as they where free :D I brought the callipers from a Porsche Breakers and he said if I gave him £400 for the calipers he would give me the arms, front hubs,spindles and rear axle :D:D... CMS Porsche breakers( recommended) I managed to get a set of 944 s2 seats off him as well, the one's with the high bolsters,they are seriously comfortable.

My attempt at building GL beetle
 

Ta Dave. Yes we will have to have a ::cheers: at a show some time.

Hows ya car,you had it out yet fella ?

looking good and keep plugging away at it. it'll all come good in the end.

Thanks for the recommendatiuon for the porsche parts mate.
Porsche stuff is super expensive here in oz and i intend to grab a bunch of stuff when im in europe.

pm sent also mate.

My attempt at building GL beetle
 

Cheers for the comments/encouragement fella's.

Few more pics of how the build has progressed.[IMG]http://i1185.photobucket.com/albums/...3.jpg~original~original[/IMG]

[IMG]http://i1185.photobucket.com/albums/...2.jpg~original~original[/IMG]

[IMG]http://i1185.photobucket.com/albums/...d.jpg~original~original[/IMG]

[IMG]http://i1185.photobucket.com/albums/...2.jpg~original~original[/IMG]
Front wings are from Day Mouldings these are made here in the UK they are a very good fit but they have also been widened/banded.

My attempt at building GL beetle
 

My original concept for the car was a stock looking one without to many body mods.However since I decided on going for a Subaru conversion I needed a way to get direct air into the front mounted radiator.I decided to loose the stock look and fit a front spoiler.I figured that as I already had these huge wheels and brakes the stock look had already gone out the window so adding a spoiler wouldn't be much more.The other reason was front end stability (form follows function )Hopefully this will direct air around the car better at high speed.I would like to fit some floor pan mods at some point to get the air under the car quicker.So I went to a car breakers in another daily 1303 and spent hours going through front spoilers to see what might work.I decided on this its off a Rover 400
This has been custom fitted by Luke at Terrys Beetle Services he grafted VW indicator lenses into it as well as extending it and making up brackets.I think it suits the round shape/lines of the 1303 but I would say that wouldnt I.:)
[IMG]http://i1185.photobucket.com/albums/...2.jpg~original~original[/IMG] It sits lower now than here in the pics as it clips the lights in this pic.
[IMG]http://i1185.photobucket.com/albums/...a.jpg~original~original[/IMG]

My attempt at building GL beetle
 

[IMG]http://i1185.photobucket.com/albums/...3.jpg~original~original[/IMG]

Nice set up. I don't think we can find those here in the US.

My attempt at building GL beetle
 

Thanks No H20.
Luke working his magic.
[IMG]http://i1185.photobucket.com/albums/...9.jpg~original~original[/IMG][IMG]http://i1185.photobucket.com/albums/...6.jpg~original~original[/IMG]
[IMG][IMG]http://i1185.photobucket.com/albums/...1.jpg~original~original[/IMG]http://i1185.photobucket.com/albums/...c.jpg~original~original[/IMG] here you can see the box section that Luke made up to direct the air to the rads.[IMG]http://i1185.photobucket.com/albums/...3.jpg~original~original[/IMG]

Paint is BMW graphite black.Its a very dark blue,at night it almost looks black but when the sun or flash from the camera hits it,it you can see the pale blue fleck.
[IMG]http://i1185.photobucket.com/albums/...8.jpg~original~original[/IMG]

[IMG]http://i1185.photobucket.com/albums/...a.jpg~original~original[/IMG][IMG]http://i1185.photobucket.com/albums/...4.jpg~original~original[/IMG]
It still needs a final polish.

Beautiful! Great work on the bumper cover too, it looks similar to porsche boxer or cayman the way the openings are shaped.

Any plans to mass produce?

My attempt at building GL beetle
 

Thanks Humble that means a lot coming from you :)
The plan is to direct the air into the rads then exit it out under the car along the pan asap hopefully via some under floor pans around the engine area.Aparantley getting the air under the car as quick as poss helps with downforce.I am hoping that the spoiler will also help get the air over and around the car quicker to add to this.

My attempt at building GL beetle
 

Hi it did cross my mind but no plans at the moment.But if I did decide to it wouldn't be too difficult as its already built and could be used as the mould :D

My attempt at building GL beetle
 

So,the Legal action I was forced to take against the so called specialist who fitted my engine is now over and settled in my favour :D

Lets hope they have a tad more respect for their customers now THEY are the ones paying out large sums of money:p:p:p:p:p:p:p.

Oh yes,life's tough when the tables get turned :bawling::bawling::bawling::bawling::bawling:

Now then where was I :D:D:D:D:D:

Loving the way this thing is turning out. What are the plans for adjusting the front camber? Seems a little to + and not enough - to me?

We are wheel brothers!

https://sphotos-a.xx.fbcdn.net/hphot...78459124_n.jpg

Jason

My attempt at building GL beetle
 

Hi Jason
Not sure if it's your car i've seen those wheels on but I have not seen many we must have the same great taste :D.

The front camber is not as bad now as it is here,also I will be fitting
some kmac Camber Adjusters.These seem like a great product and the guys who manufacture them seem to know their stuff http://www.k-mac.com.au.Another member on here Steve C has just fitted some and has come up with quite a clever solution to keeping the settings whilst removing the strutt brace.It would be great to see how he gets on with them.


Some more pics.

These are from a 944s2 turbo they are red now.[IMG]http://i1185.photobucket.com/albums/...5.jpg~original~original[/IMG]
[IMG]

http://i1185.photobucket.com/albums/...2.jpg~original~original[/IMG]

[IMG]http://i1185.photobucket.com/albums/...0.jpg~original~original[/IMG][IMG]http://i1185.photobucket.com/albums/...2.jpg~original~original[/IMG]The stance was not at its final height here, it was left like this to get it on and off the trailer without causing damage.

looks like it's really starting to take shape here. Im not normally much of a fan of too much body modification but the bumper has been done well :)

this thing when the front is down a little more to the ground will look KILLER! keep up the good work. car looks good.

My attempt at building GL beetle
 

Thanks,I am not really a fan of body mods but as I was going to fit a kameil spoiler, I just took it one step further.The last thing I wanted was a 80's style Porsche body kit look.I am pleased with how this has turned out.The original plan for the car was big type 4 with a very standard look.However as time went by I decided I wanted to drag it into the future with a modern Subaru engine, heating,wider wings,modern wheels,and comfortable seats.I think I have been lucky finding a bumper that compliments the beetle's shape so well.I know its not for everyone but that's what I like about GL we aint building Cal Look clones.I am hoping its going to follow form follows function,it directs the air where I need it to the rads and around and over the car. I am hoping this will increase downforce/stability at high speed to the normally light front end.

Very nice job. I love the bumper cover. I would like to do something similar with my project.

My attempt at building GL beetle
 

First blast at building a dash.I wanted to build one in two pieces so if there where any issues behind the dash I could remove the top section for access.The other design idea was to have the bottom section carbon and the top trimmed in leather the same as the seats.I was hoping to build the lower dash section and lay the carbon over it :lmao::lmao::lmao: if only I knew how hard this process is :confused::confused: as I say this was the first attempt.I am now on number four and i've also gained a lot more grey hairhttp://i1185.photobucket.com/albums/...d.jpg~original

[IMG]http://i1185.photobucket.com/albums/...9.jpg~original~original[/IMG]

Carbon cloth. This stuff is very difficult to handle it constantly wants to fall apart and misshape, once the weave is distorted its pretty much game over for that piece of cloth.If I where to give anyone some advise on making carbon parts I would say think very carefully about it, its very specialist.I have only posted the pics here to show how much of a pain it is.( you've been warned ) I would never of had a shot at it if I knew what was involved.But like all these things once you start you keep slogging away at it.

[IMG]http://i1185.photobucket.com/albums/...3.jpg~original~original[/IMG]


The dash on the left is the first attempt it doesn't look to bad in the pics but some areas looked terrible.this was the carbon laid on the dash.So the mdf mold/plug on the right is the beginnings of numero 2. Thanks to my mate Max he has helped tons to get this dash sorted.

[IMG]http://i1185.photobucket.com/albums/...1.jpg~original~original[/IMG]

After covering this MDF in resin you are left with a bobbly uneaven surface this is where the sanding begins LOTS of sanding and polishing Lots of that **** as well until you start to get this.
http://i1185.photobucket.com/albums/...e.jpg~original

Hi

Good idea making the dash in two sections, the stock 1303 dash is a disaster. On my can I can pull all my instruments out very easily which gives some access behind the dash.

Steve

Yes they really are a PITA.
I started making a custom one for mine as a plug for a fibreglass mould but there is just so much work in shaping it and getting it to look good as well as be functionals.

Can't wait to see what yours turns out like.

My attempt at building GL beetle
 

A few more pics of how my dash has evolved.[IMG]http://i1185.photobucket.com/albums/...5.jpg~original~original[/IMG]

The steel top section had a few mods including moving the speedo area slightly and reducing the overall width of the dash by slicing a section out next to the air vents and moving them towards the centre.
The dash now sits between the roll cage and does not run the full width of the car to the door pillars like the stock one.I then filled and shaped it to line up with the bottom section.[IMG]http://i1185.photobucket.com/albums/...a.jpg~original~original[/IMG]
[IMG]http://i1185.photobucket.com/albums/...1.jpg~original~original[/IMG]
[IMG]<a href="http://s1185.photobucket.com/user/rsg2/media/DSC01128_zpsc1fc8a8e.jpg.html" target="_blank"><img src="http://i1185.photobucket.com/albums/z351/rsg2/DSC01128_zpsc1fc8a8e.jpg" border="0" alt=" photo DSC01128_zpsc1fc8a8e.jpg"/></a>~original[/IMG]
not sure if anyones really interested in this but I thought I would post some pics anyway.[IMG]http://i1185.photobucket.com/albums/...0.jpg~original~original[/IMG][IMG]http://i1185.photobucket.com/albums/...c.jpg~original~original[/IMG]